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The automotive manufactures increase their use of lightweight materials to improve fuel economy andenergy usage has a significant influence on the choice of developing materials. To meet this requirementsmanufacturers are replacing individual body parts with lightweight metals, for these the process treating andpainting surfaces is changing. The pre-coated steels are newly developed to avoid the conventional complexand non-environmental painting process in the body-in-white car manufacturing. The development of newjoining techniques is critically needed for pre-coated steel sheets, which are electrically non-conductive materials. In the present study, dissimilar combination of pre-coated steel and galvanized steel sheets were joined bythe self-piercing rivet, adhesive bonding and hybrid joining techniques. The tensile shear test and free fallinghigh speed crash test were conducted to evaluate the mechanical properties of the joints. The highest tensilepeak load with large deformation was observed for the hybrid joining process which has attained 48%higher than the self-piercing rivet. Moreover, the hybrid and adhesive joints were observed better strainenergy compared to self-piercing rivet. The fractography analyses were revealed that the mixed mode ofcohesive and interfacial fracture for both the hybrid and adhesive bonding joints.
